1962 Borg Warner Second Gear Problems
I recently rebuilt a 1962 Borg Warner 4 speed transmission as part of a restoration on my Corvette. It shifted fine. The only problem was it popped out of second gear when I left off the gas. And the main shaft yoke splines were twisted. As part of the rebuild I replaced the main shaft with one made in Italy. I sent the shifter arms out to be modified by someone that advertises in the Driveline who claimed that it would correct the popping out of second gear problem. I also installed a locking slider on the synchronizer. When the car was first driven it was very difficult to shift into second gear unless it was double clutched or speed shifted. And it was next to impossible to down shift into second. Since then the transmission has been out numerous times and parts changed. A new second gear was installed. The shifter arms were changed. A new clutch and pressure plate was installed. Several sliders were tried along with the brass synchronizer rings. The shifter forks had a little play so they were replaced. The Borg Warner transmission has a cast iron case and it is dated 1963. However it has a 32 tooth second gear which supposedly was used only until 1962. Any ideas on what the problem might be?
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Re: 1962 Borg Warner Second Gear Problems
Dennis------
Well, with all you've already done, I really don't know what to suggest. However, you are correct about the 32 tooth second gear only being used through 1962. After that, a 30 tooth 2nd gear was used. Here's how to check which one you require: For the 32 tooth 2nd gear, your cluster gear should have the following tooth count from front to rear 28-23-20-17. For the 30 tooth 2nd gear the cluster gear count should be 30-23-20-17.
You don't need to worry about the mainshaft being a problem. The Italian-manufactured T-10 and Muncie parts are manufactured by Masiero, S.A.. They are one of the largest and well-regarded manufacturers of gears and related products in the world.In Appreciation of John Hinckley -
Re: 1962 Borg Warner Second Gear Problems
Dennis,
Before I went any further I would call Larry from D&M transmission and be specific and tell him the parts you have replaced. I bet he will have some good suggestions for you and get the transmission sorted out.Comment
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Re: 1962 Borg Warner Second Gear Problems
Dennis,
I did many Borg Warner transmissions that popped out of 2nd gear and found the problem in the syncro. The dog houses on the gear and on the slider. They need to resemble a dog house. Sounds like your 2nd gear portion of the syncro is good asnyou stated it's new. My guess is that the slider ring part of the syncro clutch is worn, ( bad dog houses). the same go's for a Munci as they were very close construction wise.
The biggest cause of the 2'nd gear pop out was grinding while missing a shift. The gear NEVER ground, it was the syncro as the forward gears are always in place on the cluster gear. The grinding rounded the dog house and when the power was reduced it would pop out. In extreme cases it could pop out under power. I remember buying the gear and having the parts guy say NSS, (not sold separately). They did sell them separately. Most novice rebuilders thought it was the brass rings in the syncro clutch but it was always on the gear and slider.
For a while GM had a separate slider for 3rd & 4th on the Munci that would fit the 1st & 2nd position but it would rub the spinning gear and make a horrible noise. The 3rd & 4th slider was different on the outside as it was a build up to strengthen the slider. GM only did that for a short time. If you take your Borg Warner out check the slider. It was possible to have the linkage out of adjustment enough to get a pop out also but it had to really be out.
DomComment
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Re: 1962 Borg Warner Second Gear Problems
Dennis,
Popping out of 2nd when backing off is almost always worn syncro teeth on 2nd gear, as others have suggested here. But you say you have replaced the gear.
So let me tell you this. Larry AT D&M is the 'go to' guy for these transmissions, as others have said.
Let tell you this too. I also bought one of the Italian made main shafts, because mine too was twisted. According to Larry, these main shafts are excellent, except of one thing. They cut the grove for front retaining ring a little too far back on the shaft. As result you will have no end play in the main shaft gear stack, and there needs to be some. The remedy is to surface grind .005 -.008 off the face of third gear. Either second or third should work, but I favor third. Measure your end clearance with a feeler gauge. I'm thinking that this might be your problem of hard shifting in and out of second. And call Larry and talk to him. He is very good to talk to.
-Dan-Comment
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